Sr TM Bayer Process

Job Purpose

The MCOE-Technology has been established as a world-class R&D facility with the primary objective of leading technology design initiatives to support all businesses of Hindalco, addressing both current and future needs.
The main purpose of this job is to lead Research, Development & innovation for Utkal, Muri, Belagavi , Renukoot and upcoming Aditya alumina refineries of Hindalco as well as for global refineries (based on requirement)  and related areas of , new process development & engineering, process debottlenecking, process design & modelling and bauxite residue utilization etc. This will include

1. Initiate and execute development projects in the areas of bauxite exploration analysis, bauxite processability studies, improvements in Bayer unit operations like desilication, digestion, bauxite residue settling, precipitation etc along with long term research on sustainable waste management.
2. Management of laboratory analysis including benchmarking with other laboratories through annual BMPT exercise and Round Robin Analysis for standardization.
3. Initiate and execute long term technology development projects for new and existing alumina refineries.
4. Interact with other research and technical agencies like CSIR labs  to take advantage of the synergy available in various fields through collaborative, sponsored and joint development projects
5. To work closely with the Environmental Research function of Hindalco Sustainability to deliver long term projects for utilization of bauxite residue in construction & other applications.
6. Work closely with technical and operations teams all the alumina refineries  to align the process function delivery with Technology Roadmap. 
7. Collaborate with the laboratories at the refineries to carry out lab audits , benchmarking and round robin exercises along with standardization of methods.
8. Work closely with the Scientists in developing and implementing analytical methods for relevant areas of Bayer process and sharing with the technical / laboratory teams at refineries.
9. Identify potential areas of opportunities for process & quality improvements to initiate research projects. Prepare CAPEX proposals along with refinery technical teams.
10. Stay updated with the latest advancements, trends, and emerging technologies in alumina industry related processes, and ensure awareness within Hindalco.
11. Managing analysis delivery of critical analytical instruments at HICA viz. Inductively Coupled Plasma (ICP), Total Organic Carbon Analyzer (TOCA), Ion Chromatography (IC), Potentiometric Titrator (PT) etc for Bayer process development by maintaining health of instruments through annual planning and procurement of critical spares.

4) Key Result Areas/Accountabilities:

The role requires to demonstrate deep technical expertise in conceptualizing and implementing cutting-edge technological advancements in the Bayer process, including advanced digestion, Precipitation, filtration, Clarification, energy recovery systems, and the integration of new technologies to optimize the Bayer process.

The role plays a critical role in maintaining process efficiency, reducing energy consumption, improving process yields, and minimizing waste generation, including red mud. This position directly influences the overall efficiency and environmental impact of the alumina production chain.

Key Result Areas/Accountabilities

Supporting Actions

Process / Technology Development and Engineering 

• Undertake development projects with respect to Bayer process in order to improve productivity / reduce cost / improve efficiency 
• Developing new processes for new product development from Bayer process & sustainable waste management 
• Design of experiments / Quality planning / Activity planning / Review etc 2. Identification of the need / Capability review / Design of experiments / Quality planning / Activity planning / Review etc.
• Leading development projects as per Technology Roadmap for all the refineries of Hindalco with respect to Bayer process in order to improve productivity / reduce cost / improve efficiency & reduce carbon footprint.

Technical Services 

• Assist plant personnel / laboratory personnel in trouble shooting 
• Review operating/ technical data from the refineries & identify improvement opportunities & execute at site.
•  Plan and conduct laboratory tests/ data analysis/ technical audits

Knowledge Management 

•  Identify training needs for others and provide training as needed 
• Guide Sr TM and TMs in the development projects and handling of instruments 
• Conduct reviews as per plan / suggest corrective / preventive actions 
• Submitting patents and publishing technical papers in national / international conferences. Leading and implementing innovation mindset in process function for achieving targets for patents/ technical papers

Exploratory Research 

• Identify long term needs of the Business and relevant exploratory projects
• Facilitate exploratory research in-house and in collaboration with others

Resource Management 

• Identify equipments for HICA keeping in mind the future needs and HICA s long term growth
• Upgrade equipments, as and when required to maintain world class standards at HICA

Collaboration and Networking 

• Foster collaborations with internal and external stakeholders, including academic institutions & industry experts. 
• Promote collaborative research, knowledge exchange and advancements in the field of Bayer process technology.

Technical Competencies

Essential technical competencies

• Expertise & knowledge of Bayer process chemistry and alumina refinery process control.
• Knowledge and experience on Chemical Engineering  process design and scale up.
• Knowledge and experience on bauxite mineralogy, processability characteristics and application in alumina refineries.
• Knowledge of chemistry and technological aspects  for grinding, digestion, bauxite residue separation & handling, filtration , precipitation and evaporation.
• Knowledge on data analytics & digitalization.

Desirable technical competencies

• Knowledge of alumina quality parameters affecting chemical grades of alumina and aluminium metal 
• Analytical methods and instruments for Bayer process research